Accurate double curvature techniques


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Ian Mantula
Ian Mantula
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Hello pattern making experts.
I am trying to make a series of plugs for some new engine bay parts for my Marcos Mantula. I'm really hope to get some advice on the best techniques for creating complex shapes with some double curvature. While I'm getting close to the shapes that i want it's still not 100% perfect. I seem to be a perfectionist without the skill to achieve the results that I am looking for. Are there any special tools available from anywhere that make it easier to shape, for example, a concave curve with a varying radius? 
I am building the plug using an MDF structure with expanded 2 part foam for the curvy parts then covering that with polyester bodyfiller. After that Easy Composites Pattern coat primer and top coat.

I'm using Permagrit tools to rough-out the shape, then various home made sanding blocks after that.

In the photo below the box with the lid is for the air-conditioning system. In front of that there is the internal mud-guard. The double curvature is essential due to the shape of the Marcos bonnet. I'll be doing a mirror-image for the other side of the car.

Perhaps the only answer is years of practice...
http://www.talkcomposites.com/Uploads/Images/ed893c8a-2c9b-4570-b0e4-d465.jpg


Thanks for any suggestions.
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VVS
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posted 9 Years Ago HOT
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Ive not used expanding foam, just recently been using the hd foam blocks to shape parts, should be similar and I'm using same kind of process to you.

Id say 80% is technique and 20% in the foam, don't apply any filler unless the foam is spot on as you are only skinning this with a millimeter of top coat.




you want to be putting the filler on super thin then sanding back very carefully.
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